Cermak Lost Foam - Lost Foam Foundry Consulting Services

The best way to predict the future is to create it.

Abraham Lincoln

Foundry Design

We can design all elements of a lost foam foundry

Foundry Engineering

Expertise in all aspects of Lost Foam Engineering

Foundry planning and realization services

We can make it happen.

More than 40 Years of Experience

With more than 40 years of experience and expertise in the foundry industry - especially Lost Foam Technology - we offer dedicated foundry solutions for aluminum, iron, steel and all other castable metals.

A Qualified Team

We have team of highly qualified experts with proven track records in management and engineering positions. Their expertise covers a wide range of functions in the cast metal industry, procurement, foundry design, project management and casting quality improvement.

Turnkey Contract

Our focus is totally on enabling our clients to meet their objectives. Whether for new (greenfield) foundries, an expansion, modernization or installation of a single equipment project in your existing foundries, we can help you with project management or turn-key contracting of your project. This will allow our clients to concentrate on their core activity: producing castings.

Our latest project

"The Turn-Key Plant"

Customer Location: the Silk Road-Hub – Horgos

9 days by Truck

12 days by rail

To Germany 5.300 km

Air Freight as well

How we machine and subassembly the components

Our target product are components difficult to cast with classic technologies sustainable with long lifespan.

We machine and sub-assemble the components.

How we " Train the Trainer"

For process start up, validation and "Train the Trainer" program, we chose the highly sophisticated PSA 1.2 l Cyclinder Head

Second casting in pilot phase:

Horgos in-house E-Motor housing, modular design with water cooling jacket

Third casting in pilot phase:

E-Motor housing FAW with water cooling jacket

Scope of our Work

1. Technology and compatibility

Technological equipment was designed by our team:

KCE GmbH in Germany.
Manufactured by experienced (20 years co-partner of GF and Disa) privately owned Mechanical engineering and manufacturing company Ma ltd.
All Automation including Robotics was designed by Siemens and ABB trained and experienced (10+ years working as integrator for ABB and Siemens) Kongs Team. Both companies are bound to Cermak E-Tech-Horgos with long term service contracts.

2. Equipment and design

In line of European automotive specifications and Chinese safety codes.

Selected suppliers :

Siemens, ABB-Robotics, Festo, Norgren, Parker, Bosch, Gemue, Spirax, Sommer, Shott

3. Projection of plant capacity

Phase I: 100 Flask per hour ( 1.000.000 cylinder heads / a with 2-on cluster)
Phase II: 100 Flask per hour ( 1.000.000 head’s )
Phase III: 100 Flask per hour ( 1.000.000 head’s)

4. Raw materials and consumables

EPS – Styrochem and Taiwan cup bead producer
Coating- ASK – Germany and ASK China
Hot melt glue – Ruderer/Fueller

5. Software

For mechanical design and tooling
Pro-Engineer
E-plan for controls

6. Quality management

Quality Handbook is ready for audit, ISO 9004 and …….application on the way.

7. Remote process

Monitor/control
All control have SCADA capabilities, remote monitoring and sharing HMI screen’s.
Virtual auditing „walk through plant“ will be realized in 2022

8. Support from outside

MOU with IFAM institute was signed, first license for cast components is in process
Expert remote team is set up to support with Process and product control
Close cooperation and consulting service with Karel Cermak Engineering GmbH is operational, Import and export department is experienced.